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Copyright 2015, FCA US LLC, All Rights Reserved (wah)
December 2015 Dealer Service Instructions for:
Safety Recall R52 / NHTSA 15V-592
Powertrain Control Module
2016 (DJ) RAM Truck (2500 series)
(D2) RAM Truck (3500 series)
(DD) RAM Cab Chassis (3500 series)
(DP) RAM Cab Chassis (4500/5500 series)
NOTE: This recall applies only to the above vehicles equipped with a 6.7L
Cummins Turbo Diesel engine (sales code ETK) built at the Saltillo Assembly
Plant (“G” in the 11th
VIN Position) from July 31, 2015 through August 13, 2015
(MDH 073109 through 081300).
The Powertrain Control Module (PCM) on about 40 of the above vehicles may
have been damaged during the manufacturing process. One of the PCM printed
circuit board retaining screws may have damaged the edge of the printed circuit
board. This can cause a short circuit to ground condition within the PCM. Should
the printed circuit board short to ground, the engine could stall. An engine stall
could cause a crash without warning.
Models
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Federal law requires you to complete this recall service on these
vehicles before retail delivery. Dealers should also consider this requirement to
apply to used vehicle inventory and should perform this recall on vehicles in for
service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
Safety Recall R52 – Powertrain Control Module Page 2
The PCM on all involved vehicles must be replaced.
Part Number Description
68293842AB Module, Generic Engine Control
Each dealer to whom vehicles in the recall were assigned will receive enough
Engine Control Modules to service about 20% of those vehicles.
06506293AA Pin, Plastic Push (MSQ = 8)
No parts return required for this campaign.
The following special tools are required to perform this repair:
NPN wiTECH VCI Pod Kit
NPN Laptop Computer
NPN wiTECH Software
Repair
Parts Information
Parts Return
Special Tools
Safety Recall R52 – Powertrain Control Module Page 3
A. Replace Powertrain Control Module
NOTE: To avoid possible voltage spike damage to the Powertrain Control
Module (PCM), ignition key must be off, and both negative battery cables
must be disconnected before unplugging PCM harness connectors.
1. Place the vehicle on an appropriate hoist.
2. Open the hood.
3. Disconnect both negative battery cables.
4. Remove and save the left front tire.
5. Remove and save the left front plastic wheel liner.
6. Disconnect the frame ground wire.
7. Remove and save the four PCM electrical connector retaining bolts (Figure 1).
Service Procedure
Figure 1 – Powertrain Control Module Electrical Connectors (body removed for photographic purposes only)
ELECTRICAL CONNECTOR
RETAINING BOLTS
ELECTRICAL CONNECTOR LOCK
BAR
ELECTRICAL CONNECTOR LOCK
BAR
POWERTRAIN CONTROL MODULE ELECTRICAL
CONNECTORS
Safety Recall R52 – Powertrain Control Module Page 4
8. Lift the lock bar and disconnect the two PCM harness electrical connectors
(Figure 1).
CAUTION: If the PCM electrical connector latch is packed with dirt or
debris, clean the electrical connector latch with electrical contact cleaner.
Damage to the PCM electrical connector housing may result if a dirty
PCM electrical connector is forced open.
9. Working through the left front wheel opening, remove and save the four PCM
mounting bolts (Figure 2).
10. Remove and discard the original PCM from the engine.
11. Place the new PCM into position on the engine block.
12. Install the four PCM mounting bolts. Tighten the PCM mounting bolts to
18 ft. lbs. (24 N·m).
Service Procedure (Continued)
Figure 2 – Powertrain Control Module Mounting Bolts
POWERTRAIN CONTROL MODULE
RETAINING BOLTS
POWERTRAIN CONTROL MODULE
Safety Recall R52 – Powertrain Control Module Page 5
13. Install the two PCM harness electrical connectors to the PCM electrical
receptacles and engage the electrical connector lock bars.
14. Install the four PCM electrical connector retaining bolts. Tighten the bolts to
80 in. lbs. (9 N·m).
15. Install frame ground wire and retaining nut. Tighten nut to 80 in. lbs. (9 N·m).
16. Install the left front plastic wheel liner.
17. Install the left front wheel. Tighten the lug nuts to 135 ft. lbs. (100 N·m).
18. Lower the vehicle from the hoist.
19. Connect both negative battery cables.
20. Continue with Section B. Program the Powertrain Control Module.
Service Procedure (Continued)
Safety Recall R52 – Powertrain Control Module Page 6
B. Program the Powertrain Control Module
1. Connect a battery charger to the vehicle.
2. Start a wiTECH scan tool session.
3. Connect a Micro Pod II to the data link connector on the vehicle.
4. From the vehicle view screen, select the “Continue” button on the pop-up
screen.
5. Manually enter the entire Vehicle Identification Number (VIN) and select the
“Continue” button.
6. Select the “Close” button.
7. Record the engine reference number located on the white label on the engine
valve cover (Figure 3).
Service Procedure (Continued)
Figure 3 – Engine Reference Number Location
(engine beauty cover removed for photographic purposes only)
ENGINE REFERENCE
NUMBER LABEL
Safety Recall R52 – Powertrain Control Module Page 7
8. From the vehicle view screen, select the “PCM” icon.
9. Highlight the flash file that matches the reference number recorded in Step 7 of
this procedure.
10. Click the green arrow on the file highlighted to begin the programming process.
11. Follow the screen prompts to complete the programing of the PCM.
12. Use the wiTECH scan tool to erase any Diagnostic Trouble Codes (DTC's)
from PCM.
13. After programming the PCM:
For vehicles equipped with an 68RFE automatic transmission, allow the
module to fully power down for 10 minutes.
For vehicles equipped with an AS69RC Aisin automatic transmission,
automatic transmission equipped vehicles, allow the module to fully power
down for 75 seconds.
For vehicles equipped with a manual transmission, allow the module to
fully power down for 75 seconds.
14. From the PCM “Misc. Functions” tab, select “Check PCM VIN” from the list.
15. Follow the screen prompts to complete the task.
16. From the PCM “Misc. Functions” tab, select “PCM Configuration” from the
list.
17. Follow the screen prompts to complete the task.
18. Use the wiTECH scan tool to erase any Diagnostic Trouble Codes (DTC's)
from PCM.
19. For vehicles equipped with a 68RFE automatic transmissions, continue with
Section C. 68 RFE Transmission Quick Learn Procedure.
20. For vehicles equipped with an AS69RC Aisin automatic transmission or a
manual transmission, no further action is required. Remove the wiTECH scan
tool from the vehicle and return the vehicle to the customer.
Service Procedure (Continued)
Safety Recall R52 – Powertrain Control Module Page 8
C. 68RFE Transmission Quick Learn Procedure
NOTE: Only vehicles equipped with a 68RFE automatic transmission require
this procedure.
1. From the PCM “Misc. Functions” tab, select “Quick Learn RFE” from the
list.
2. Follow the screen prompts to complete the task.
3. Use the wiTECH scan tool to erase any Diagnostic Trouble Codes (DTC's)
from PCM.
4. Remove the wiTECH scan tool from the vehicle.
5. Return the vehicle to the customer.
Service Procedure (Continued)
Safety Recall R52 – Powertrain Control Module Page 9
This recall is subject to the State of California Registration Renewal/Emissions
Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of
Correction Form (Form No. 81-016-1053) and supply it to vehicle owners
residing in the state of California for proof that this recall has been performed
when they renew the vehicle registration.
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by FCA to record recall service completions and provide
dealer payments.
Use the following labor operation number and time allowance:
Labor Operation Time
Number Allowance
Replace the PCM
(includes programming) 08-R5-21-82 1.1 hours
Optional Equipment
With 68RFE automatic transmission 08-R5-21-60 0.3 hours
Add the cost of the recall parts package plus applicable dealer allowance to your
claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete recall claim processing instructions.
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.
Complete Proof of Correction Form for California Residents
Completion Reporting and Reimbursement
Dealer Notification
Safety Recall R52 – Powertrain Control Module Page 10
All involved vehicle owners known to FCA are being notified of the service
requirement by first class mail. They are requested to schedule appointments for
this service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC
Owner Notification and Service Scheduling
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
______________________________________________________________________________________
IMPORTANT SAFETY RECALL R52 / NHTSA 15V-592
This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Dear: (Name)
FCA has decided that a defect, which relates to motor vehicle safety, exists in certain 2016 model year RAM
trucks equipped with a 6.7L Cummins Turbo Diesel engine.
The problem is... The Powertrain Control Module (PCM) on your vehicles may have been damaged
during the manufacturing process. One of the PCM printed circuit board retaining
screws may have damaged the edge of the printed circuit board. This can cause a short
circuit to ground condition within the PCM. Should the printed circuit board short to
ground, the engine could stall. An engine stall could cause a crash without warning.
What your dealer
will do... FCA will repair your vehicle free of charge. To do this, your dealer will replace the
Powertrain Control Module. The work will take about 1.5 hours to complete. However,
additional time may be necessary depending on service schedules.
What you must do
to ensure your
safety...
Simply contact your Chrysler, Jeep, Dodge or RAM dealer right away to schedule a
service appointment. Ask the dealer to hold the parts for your vehicle or to order them
before your appointment. Please bring this letter with you to your dealer.
If you need help...
California
residents…
If you have questions or concerns which your dealer is unable to resolve, please contact the
FCA Group Recall Assistance Center at either fcarecalls.com or 1-800-853-1403.
The State of California requires the completion of emission recall repairs prior to vehicle
registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of
Correction Form after the recall service is performed. Be sure to save this form since the
California Department of Motor Vehicles may require that you supply it as proof that the
recall has been performed.
Please help us update our records by filling out the attached prepaid postcard if any of the conditions listed on the
card apply to you or your vehicle. If you have further questions go to fcarecalls.com.
If you have already experienced this specific condition and have paid to have it repaired, you may visit
www.fcarecallreimbursement.com to submit your reimbursement request online or you can mail your original
receipts and proof of payment to the following address for reimbursement consideration: FCA Customer
Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Once we
receive and verify the required documents, reimbursement will be sent to you within 60 days. If you’ve had
previous repairs and/or reimbursement you may still need to have the recall repair performed on your vehicle.
If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit
a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave.,
S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY 1-800-424-9153), or go to safercar.gov.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention
to this important matter.
Customer Services / Field Operations
FCA US LLC
Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
POWERTRAIN CONTROL MODULE
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